Rotary ultrasonic machining of CFRP: A comparison with twist drilling

Cong, Weilong; Pei, Zhijian; Qian, Feng; Deines, Timothy W.; Treadwell, C.

doi:10.1177/0731684411427419

Cited by 65 publications

(26 citation statements)

References 17 publications

(1 reference statement)

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“…Effects of input variables (including ultrasonic power, tool rotation speed, feedrate, and coolant type) on output variables (including cutting force, torque, surface roughness, delamination, and tool wear) have been investigated [Li et al 2007;Cong et al 2011abcd, Feng et al 2011. Using the same CFRP workpiece material and similar machining conditions, twist drilling and RUM have been compared [Cong et al 2011d]. Also, to reduce the costs associated with cutting fluids, RUM of CFRP using cold air as coolant has been studied [Cong et al 2011abc].…”

Section: Introductionmentioning

confidence: 99%

Rotary ultrasonic machining of CFRP composites: A study on power consumption

et al. 2012

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Carbon fiber reinforced plastic (CFRP) composites are very difficult to machine. A large number of holes need to be drilled in CFRP for many applications. Therefore, so it is important to develop cost-effective drilling processes. CFRP has been drilled by rotary ultrasonic machining (RUM) successfully. The literature has reports about the effects of input variables on output variables (including cutting force, torque, surface roughness, tool wear, and workpiece delamination) in RUM of CFRP. However, there are no reports on power consumption in RUM of CFRP. This paper reports the first study on power consumption in RUM of CFRP. It reports an experimental investigation on effects of input variables (ultrasonic power, tool rotation speed, feedrate, and type of CFRP) on power consumption of each component (including ultrasonic power supply, spindle motor, coolant pump, and air compressor) and the entire RUM system.

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Section: Introductionmentioning

confidence: 99%

Rotary ultrasonic machining of CFRP composites: A study on power consumption

et al. 2012

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“…The explanations of the effects on the cutting forces can also be used to explain the effects on the torque. 23,24,31,32,51,52 Effects of abrasive size. Figure 13 shows the effects of abrasive size on the torque.…”

Section: Effects On Torquementioning

confidence: 99%

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Wang

Ning

et al. 2016

Advances in Mechanical Engineering

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Carbon fiber-reinforced plastic composites have many superior properties, including low density, high strength-toweight ratio, and good durability, which make them attractive in many industries. However, due to anisotropic properties, high stiffness, and high abrasiveness of carbon fibers in carbon fiber-reinforced plastic, high cutting force, high tool wear, and high surface roughness are always caused in conventional machining processes. This article reports an investigation using rotary ultrasonic machining in surface grinding of carbon fiber-reinforced plastic composites in order to develop an effective and high-quality surface grinding process. In rotary ultrasonic machining surface grinding of carbon fiber-reinforced plastic composites, tool selection is of great importance since tool variables will significantly affect output variables. In this work, the effects of tool variables, including abrasive size, abrasive concentration, number of slots, and tool end geometry, on machining performances, including the cutting force, torque, and surface roughness, are experimentally studied. The results show that lower cutting forces and torque are generated by the tool with higher abrasive size, lower abrasive concentration, and two slots. Lower surface roughness is generated by the tool with smaller abrasive size, smaller abrasive concentration, two slots, and convex end geometry. This investigation will provide guides for tool selections during rotary ultrasonic machining surface grinding of carbon fiber-reinforced plastic composites.

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“…Seven brittle materials (Al 2 O 3 , ZrO 2 / Al 2 O 3 , dental ceramics, SiC, poly-crystalline, CMC, and silicon), two ductile materials (Ti and stainless steel) and two carbon fibre composites (C/C, CFRP) were studied. Seven of the 13 input variables were studied for ductile materials, six of them for brittle materials and only two of them for carbon fibre composites (Cong et al, 2011(Cong et al, , 2013a(Cong et al, , 2012a(Cong et al, , 2012b(Cong et al, , 2012c2012d;Ma, 2013). There is a phenomena that cutting force in UVAG was lower than that in traditional diamond grinding.…”

Section: Experimental Investigations On Cutting Force and Torquementioning

confidence: 99%

“…In addition, torque decreased with the increase of ultrasonic vibration amplitude and tool rotational speed and the decrease of feedrate in UVAG of carbon fibre composites. Also, using variable feedrate method (explained in Section 9) or cutting fluid, torque could be lower than using a fixed feedrate method or cold air (Cong et al, 2011(Cong et al, , 2013a(Cong et al, , 2012c(Cong et al, , 2012d.…”

Section: Figure 6 Schematic Illustrations Of the Drilling Processesmentioning

confidence: 99%

“…It is reported that UVAG has six to ten times higher MRR than traditional grinding , and it is about ten times faster than ultrasonic machining (USM) (Cleave, 1976). Tool pressure and torque in UVAG are low (Cleave, 1976;Cusumano et al, 1974;Cong et al, 2011Cong et al, , 2013aCong et al, , 2012cCong et al, , 2012d: lower pressure is especially helpful when drilling small holes, deep holes, or adjacent holes with thin dividing walls (Cleave, 1976). UVAG also has reduced edge chipping, breakout and damage (Cleave, 1976).…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Experimental investigations on core drilling by ultrasonic-vibration-assisted grinding for hard-to-machine materials - a review

Qin

Lei

Pei

2016

IJMR

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Ultrasonic-vibration-assisted grinding (UVAG), a hybrid machining process combining material removal mechanisms of diamond grinding and ultrasonic machining, has been used to machine various hard-to-machine materials. Large amount of research work on UVAG has been carried out since it is invented. However there are few review papers to cover the current literature on UVAG. The emphasis of this literature review is the experimental investigations of the drilling process with ultrasonic vibration using a core drill with metal-bonded diamond abrasives. Experimental results are summarised and compared. The inconsistent results and their reasons are discussed. Furthermore, directions of future research on UVAG are also presented.

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Rotary ultrasonic machining of CFRP: A comparison with twist drilling

Cited by 65 publications

References 17 publications

Rotary ultrasonic machining of CFRP composites: A study on power consumption

Rotary ultrasonic machining of CFRP composites: A study on power consumption

Surface grinding of carbon fiber–reinforced plastic composites using rotary ultrasonic machining: Effects of tool variables

Experimental investigations on core drilling by ultrasonic-vibration-assisted grinding for hard-to-machine materials - a review

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